Process to control hi concentration in residuum stream

ABSTRACT

A process directed to acetic acid production comprising providing a feed stream comprising methyl iodide, water, acetic acid, methyl acetate, and at least one PRC to a distillation column comprising a distillation zone and a bottom sump zone and distilling the feed stream at a pressure and a temperature sufficient to produce an overhead stream comprising methyl iodide and at least one PRC, and a residuum stream flowing from the bottom sump zone comprising water and greater than or equal to about 0.11 weight percent HI is disclosed herein.

RELATED APPLICATIONS

This application claims priority benefit to U.S. Ser. No. 14/724,197, filed May 28, 2015, which claims priority benefit to U.S. Provisional Application No. 62/112,120, filed Feb. 4, 2015, the disclosures of which are fully incorporated herein by reference.

BACKGROUND

Acetic acid production by carbonylation includes continuously reacting methanol and carbon monoxide in the presence of a catalyst in a reactor. The reaction mixture present in the reactor comprises a transition metal, which may be a Group VIII metal, which may be iridium and/or rhodium or nickel, and may further include one or more solvents, water, various stabilizers, co-catalysts, promoters, and the like. Reaction mixtures known in the art may comprise acetic acid, methyl acetate, methyl iodide, hydrogen iodide, a hydrogen iodide promoter, and the like.

A complex network of inter-dependent equilibria involving liquid acetic acid reaction components exists within the reaction mixture present in the reactor, which include those directed to the formation of acetic acid, as well as those directed to the formation of various impurities which are also produced in the reactor. Impurities which may be present in acetic acid include permanganate reducing compounds (PRCs) such as acetaldehyde.

Hydrogen iodide, HI, whether present in molecular form as hydrogen iodide or dissociated in a solvent as hydriodic acid, is present in the reaction mixture according to various production schemes. However, HI is highly corrosive to metals and presents various challenges in acetic acid production.

Attempts in the art are directed to minimizing HI outside of the reactor, with the ultimate goal of eliminating it outside of the reactor. Examples include processes directed to injecting methanol into a distillation column with the purported intention of reacting the methanol with the HI present therein to form methyl iodide and water. (cf. JP2000-72712, Japanese application 10-244590, filed Aug. 31, 1998, the entire contents and disclosure of which is hereby incorporated by reference). However, processes directed to minimizing HI to reduce or eliminate corrosion issues failed to realize benefits associated with particular concentrations of HI outside the reactor. There is a need to control HI concentrations within particular ranges in various aspects of an acetic acid production process.

SUMMARY

In embodiments according to the instant disclosure, methods to produce acetic acid comprise a process wherein the concentration of HI is controlled above a minimum concentration and/or within a selected concentration range above the minimum concentration in one or more streams outside of the carbonylation reactor. In particular, in a distillation column utilized in an aldehyde removal process.

In embodiments, a process comprises providing a feed stream comprising methyl iodide, water, acetic acid, methyl acetate, and at least one PRC to a distillation column comprising a distillation zone and a bottom sump zone, distilling the feed stream at a pressure and a temperature sufficient to produce an overhead stream comprising methyl iodide and at least one PRC, and a residuum stream flowing from the bottom sump zone comprising water and greater than or equal to about 0.11 weight percent HI, wherein a total amount of HI exiting the distillation column in the overhead stream and the residuum stream is greater than the amount of HI entering the distillation column, if any, in the feed stream.

In embodiments, a process comprises distilling a portion of a reaction medium of a carbonylation reactor in a first column to yield an acetic acid stream and a first overhead stream comprising methyl iodide, water, acetic acid, methyl acetate, and at least one PRC; directing a second column feed stream comprising or derived from the first overhead stream into a second distillation column comprising a distillation zone and a bottom sump zone; distilling the second column feed stream at a pressure and a temperature sufficient to produce a second column overhead stream comprising methyl iodide and at least one PRC, and a second column residuum stream flowing from the bottom sump zone comprising water and greater than or equal to about 0.11 weight percent HI; extracting at least a portion of the second column overhead stream comprising methyl iodide and at least one PRC with water to produce an aqueous waste stream comprising the at least one PRC, and a raffinate stream comprising methyl iodide; and directing at least a first portion of the raffinate stream back into the second distillation column.

In still other embodiments, a process comprises distilling a portion of a reaction medium of a carbonylation reactor in a first distillation column to yield an acetic acid stream and a first overhead stream comprising methyl iodide, water, acetic acid, methyl acetate, and at least one PRC; directing a second column feed stream comprising or derived from the first overhead stream into a second distillation column comprising a distillation zone and a bottom sump zone; distilling the second column feed stream at a pressure and a temperature sufficient to produce a second column overhead stream comprising methyl iodide, dimethyl ether, and at least one PRC, and a second column residuum stream flowing from the bottom sump zone comprising water and from about 0.11 weight percent to about 0.9 weight percent HI; directing a top flush stream comprising water into the distillation zone at a mass flow rate greater than or equal to 0.1% of the mass flow rate of the second column feed stream; and directing a bottom flush stream comprising acetic acid into the distillation zone and/or the bottom sump zone at a mass flow rate greater than or equal to 0.1% of the mass flow rate of the second column feed stream.

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a schematic diagram of a process to produce acetic acid according to an embodiment;

FIG. 2 is a schematic diagram of an alternative purification process according to an embodiment;

FIG. 3 is a cross sectional diagram of a second distillation column according to an embodiment;

FIG. 4 is a cross sectional diagram of a liquid redistributor of a second distillation column according to an embodiment;

FIG. 5 is a cross sectional diagram of a liquid redistributor of a second distillation column according to another embodiment; and

FIG. 6 is a cross sectional diagram of a liquid redistributor of a second distillation column according to another embodiment.

DETAILED DESCRIPTION

At the outset, it should be noted that in the development of any such actual embodiment, numerous implementation—specific decisions must be made to achieve the developer's specific goals, such as compliance with system related and business related constraints, which will vary from one implementation to another. In addition, the processes disclosed herein can also comprise components other than those cited or specifically referred to, as is apparent to one having average or reasonable skill in the art.

In the summary and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific data points, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors possessed knowledge of the entire range and all points within the range.

Throughout the entire specification, including the claims, the following terms have the indicated meanings unless otherwise specified.

As used in the specification and claims, “near” is inclusive of “at.” The term “and/or” refers to both the inclusive “and” case and the exclusive “or” case, and is used herein for brevity. For example, a mixture comprising acetic acid and/or methyl acetate may comprise acetic acid alone, methyl acetate alone, or both acetic acid and methyl acetate.

All percentages are expressed as weight percent (wt %), based on the total weight of the particular stream or composition present, unless otherwise noted. Room temperature is 25° C. and atmospheric pressure is 101.325 kPa unless otherwise noted.

For purposes herein:

-   -   acetic acid may be abbreviated as “AcOH”;     -   acetaldehyde may be abbreviated as “AcH”;     -   methyl acetate may be abbreviated “MeAc”;     -   methanol may be abbreviated “MeOH”;     -   methyl iodide may be abbreviated as “MeI”;     -   carbon monoxide may be abbreviated “CO”; and     -   dimethyl ether may be abbreviated “DME”.

HI refers to either molecular hydrogen iodide or dissociated hydriodic acid when at least partially ionized in a polar medium, typically a medium comprising at least some water. Unless otherwise specified, the two are referred to interchangeably. Unless otherwise specified, HI concentration is determined via acid-base titration using a potentiometric end point. In particular, HI concentration is determined via titration with a standard lithium acetate solution to a potentiometric end point. It is to be understood that for purposes herein, the concentration of HI is not determined by subtracting a concentration of iodide assumed to be associated with a measurement of corrosion metals or other non H+ cations from the total ionic iodide present in a sample.

It is to be understood that HI concentration does not refer to iodide ion concentration. HI concentration specifically refers to HI concentration as determined via potentiometric titration.

This subtraction method is an unreliable and imprecise method to determine relatively lower HI concentrations (i.e., less than about 5 weight percent) due to the fact that it assumes all non-H+ cations (such as cations of Fe, Ni, Cr, Mo) are associated with iodide anion exclusively. In reality, a significant portion of the metal cations in this process can be associated with acetate anion. Additionally, many of these metal cations have multiple valence states, which adds even more unreliability to the assumption on the amount of iodide anion which could be associated with these metals. Ultimately, this method gives rise to an unreliable determination of the actual HI concentration, especially in view of the ability to perform a simple titration directly representative of the HI concentration.

For purposes herein, an “overhead” of a distillation column refers to at least one of the lower boiling condensable fractions which exits at or near the top, (e.g., proximate to the top), of the distillation column, and/or the condensed form of that stream or composition. Obviously, all fractions are ultimately condensable, yet for purposes herein, a condensable fraction is condensable under the conditions present in the process as readily understood by one of skill in the art. Examples of non-condensable fractions may include nitrogen, hydrogen, and the like. Likewise, an overhead stream may be taken just below the upper most exit of a distillation column, for example, wherein the lowest boiling fraction is a non-condensable stream or represents a de-minimis stream, as would be readily understood by one of reasonable skill in the art.

The residuum of a distillation column refers to one or more of the highest boiling fractions which exit at or near the bottom of the distillation column, also referred to herein as flowing from the bottom sump of the column. It is to be understood that a residuum may be taken from just above the very bottom exit of a distillation column, for example, wherein the very bottom fraction produced by the column is a salt, an unusable tar, a solid waste product, or a de-minimis stream as would be readily understood by one of reasonable skill in the art.

For purposes herein, distillation columns comprise a distillation zone and a bottom sump zone. The distillation zone includes everything above the bottom sump zone, i.e., between the bottom sump zone and the top of the column. For purposes herein, the bottom sump zone refers to the lower portion of the distillation column in which a liquid reservoir of the higher boiling components is present (e.g., the bottom of a distillation column) from which the bottom or residuum stream flows upon exiting the column. The bottom sump zone may include reboilers, control equipment, and the like.

It is to be understood that the term “passages”, “flow paths”, “flow conduits”, and the like in relation to internal components of a distillation column are used interchangeably to refer to holes, tubes, channels, slits, drains, and the like, which are disposed through and/or which provide a path for liquid and/or vapor to move from one side of the internal component to the other side of the internal component. Examples of passages disposed through a structure such as a liquid distributor of a distillation column include drain holes, drain tubes, drain slits, and the like, which allow a liquid to flow through the structure from one side to another.

Average residence time is defined as the sum total of all liquid volume hold-up for a given phase within a distillation zone divided by the average flow rate of that phase through the distillation zone. The hold-up volume for a given phase can include liquid volume contained in the various internal components of the column including collectors, distributors and the like, as well as liquid contained on trays, within downcomers, and/or within structured or random packed bed sections.

The average total residence time of the feed stream in the distillation zone of the column is necessarily less than (and does not refer to) the total residence time of the feed stream within the distillation column. The total residence time of a stream in a distillation column is the sum of both the total residence time of the feed stream in the distillation zone and the total residence time of the feed stream in the bottom sump zone of the column.

As used herein, internal components located within a distillation zone of a column include packing sections, liquid distributors, liquid collectors, liquid redistributors, trays, supports, and the like.

As used herein, mass flow rate refers to kg/hr unless otherwise stated, and may be determined directly or calculated from volumetric measurements.

As used herein, a carbonylatable reactant is any material which reacts with carbon monoxide under reaction conditions to produce acetic acid, or the intended product. Carbonylatable reactants include methanol, methyl acetate, dimethyl ether, methyl formate, and the like.

As used herein, when at least a portion of a stream or other composition is further processed, such as by being recycled or directed back into another portion of the process, it is to be understood that a “portion” refers to an aliquot of the stream or composition. Stated another way, a “portion” refers to a portion of the entire mass flow of the stream or a portion of the entire composition. It is to be expressly understood that a “portion” of a stream or composition does not refer to selective components present therein. Accordingly, recycle of a portion of stream does not include any process in which components in the stream at the origination point are not present at the disposition point.

When a portion of a stream or composition is directly recycled or otherwise directed to a disposition point, the mass of each component originally present in the stream is present at the disposition point at the same relative proportions.

A portion of a stream or composition which is indirectly recycled or otherwise directed may be combined with other streams, yet the absolute mass of each and every component present in the original stream is still present at the disposition point, and the changes to the overall composition are the result of combining the particular stream with others.

As used herein, a stream or composition “derived” from another stream may include the entire stream or may include less than all of the individual components initially present in the stream. Accordingly, recycle of a stream derived from another stream does not necessarily require the mass of each component originally present in the stream to be present at the disposition point. A stream or composition “derived” from a particular stream may thus include a stream which is subject to further processing or purification prior to disposition. For example, a stream which is distilled prior to being recycled to a final disposition point is derived from the original stream.

For purposes herein, permanganate reducing compounds (PRCs) include acetaldehyde, acetone, methyl ethyl ketone, butyraldehyde, crotonaldehyde, 2-ethyl crotonaldehyde, 2-ethyl butyraldehyde, and the like, and the aldol and cross aldol condensation products thereof. In embodiments, PRC's may be determined by JIS K1351 (2007).

HI has physical properties which are generally considered detrimental to various process components typically present in commercial acetic acid processes due to corrosion issues. In particular, the presence of HI in distillation columns is considered detrimental, especially to heat exchange surfaces such as reboilers and the like.

However, it has been discovered that when HI is present at particular concentrations within one or more streams in the distillation system, of an acetic acid process, one or more previously unknown benefits are realized. For example, it has been suggested that HI is instrumental in the formation of dimethyl ether (DME) under conditions present within a distillation column of an aldehyde removal system (ARS) according to the equilibrium equations:

This dimethyl ether unexpectedly functions to lower the concentration of methyl iodide in the aqueous waste streams produced by such aldehyde removal systems as disclosed in U.S. Pat. No. 7,223,883, U.S. Pat. No. 7,223,886, and U.S. Pat. No. 8,076,507, and the like, all of which are incorporated by reference herein. Accordingly, prior art disclosures directed to eliminating HI fail to realize the benefits which flow from HI concentrations according to embodiments disclosed herein. Embodiments disclosed herein further provide methods by which the formation of HI within the distillation column of the aldehyde removal system, and the concentration of HI within the sump of this distillation column may be controlled. By controlling the HI concentration in the sump of the ARS distillation column, the amount of DME produced in the column may be controlled to obtain the benefits which flow therefrom.

In embodiments, a process comprises providing a feed stream comprising methyl iodide, water, acetic acid, methyl acetate, and at least one PRC to a distillation column comprising a distillation zone and a bottom sump zone; distilling the feed stream at a pressure and a temperature sufficient to produce an overhead stream comprising methyl iodide and at least one PRC, and a residuum stream flowing from the bottom sump zone comprising water and greater than or equal to about 0.11 weight percent HI. In embodiments, the residuum stream comprises about 0.6 weight percent HI to about 1.2 weight percent HI.

In embodiments, an average liquid phase residence time within the distillation zone is about 1 minute to about 60 minutes. In embodiments, the liquid phase present within the distillation column comprises a first liquid phase comprising greater than about 50 weight percent water and a second liquid phase comprising greater than about 50 weight percent methyl iodide; wherein the distillation zone comprises a plurality of internal components, each having a corresponding component liquid retention volume; and wherein each component liquid retention volume has an average residence time of the first liquid phase and an average residence time of the second liquid phase of less than 30 minutes. In embodiments, the average residence time of the first liquid phase is greater than or equal to the average residence time of the second liquid phase within the component liquid retention volume of at least one internal component.

In embodiments, the process may further comprise directing a top flush stream comprising water into the distillation zone. In embodiments, a mass flow rate of the top flush stream is greater than or equal to about 0.1 percent of the mass flow rate of the feed stream. In embodiments, the top flush stream comprises greater than or equal to about 20 weight percent water, a portion of the bottom residuum stream, or a combination thereof.

In embodiments, the process may further comprise directing a bottom flush stream comprising acetic acid into the distillation zone, the bottom sump zone, or both. In embodiments, the bottom flush stream comprises greater than or equal to about 20 weight percent acetic acid. In embodiments, a mass flow rate of the bottom flush stream is greater than or equal to about 0.1 percent of the mass flow rate of the feed stream.

In embodiments, the overhead stream comprises dimethyl ether.

In embodiments, a process comprises carbonylating a reaction medium comprising a reactant feed stream comprising methanol, methyl acetate, dimethyl ether, or mixtures thereof, water, a rhodium catalyst, an iodide salt and methyl iodide to form acetic acid; distilling a stream derived from the reaction medium in a first column to yield an acetic acid side stream which is further purified to produce a product acetic acid stream, and a first overhead stream comprising methyl iodide, water, acetic acid, methyl acetate, and at least one PRC; biphasically separating the first overhead stream into a light phase comprising methyl iodide, acetic acid, methyl acetate, at least one PRC, and greater than about 30 wt % water, and a heavy phase comprising water, acetic acid, methyl acetate, at least one PRC, and greater than about 30 wt % methyl iodide; directing a second column feed stream comprising or derived from a portion of the light phase, the heavy phase, or a combination thereof, into a second distillation column comprising a distillation zone and a bottom sump zone; and distilling the second column feed stream at a pressure and a temperature sufficient to produce a second column overhead stream comprising methyl iodide, and at least one PRC, and a second column residuum stream flowing out of the second column from the bottom sump zone comprising water and from 0.11 weight percent to 0.9 weight percent HI, wherein a total amount of HI exiting the distillation column in the overhead stream and the residuum stream is greater than an amount of HI entering the distillation column, if any, in the feed stream.

In embodiments, the process may further comprise directing a top flush stream comprising water into the distillation zone at a mass flow rate greater than or equal to 0.1% of the mass flow rate of the second column feed stream; directing a bottom flush stream comprising acetic acid into the distillation zone and/or the bottom sump zone at a mass flow rate greater than or equal to 0.1% of the mass flow rate of the second column feed stream, or a combination thereof.

In embodiments, a bottom temperature of the second distillation column, a pressure of the second distillation column, a composition of the top flush stream, the mass flow rate of the top flush stream, a composition of the bottom flush stream, the mass flow rate of the bottom flush stream, an average liquid phase residence time in the distillation zone, or a combination thereof, are controlled (e.g., selected) to produce the residuum stream comprising about 0.11 weight percent HI to less than or equal to 0.9 weight percent HI.

In embodiments, the process may further comprise extracting at least a portion of the second column overhead stream comprising methyl iodide and at least one PRC with water to produce an aqueous waste stream comprising the at least one PRC, and a raffinate stream comprising methyl iodide; and directing at least a first portion of the raffinate stream back into the second distillation column. In embodiments, the second column feed stream comprises at least 10 wt % of the light phase and at least 10 wt % of the heavy phase, based on the total amount of the second column feed stream.

In embodiments, the second column overhead comprises dimethyl ether. In embodiments, the process may further comprise directing a second portion of the raffinate stream comprising methyl iodide and dimethyl ether back into the reaction medium. In embodiments, a mass flow rate of the first portion of the raffinate stream is greater than or equal to a mass flow rate of the second portion of the raffinate stream.

In embodiments, an average liquid phase residence time within the distillation zone of the process is about 1 minute to about 60 minutes. In embodiments, the liquid phase comprises a first liquid phase comprising greater than about 50 weight percent water and a second liquid phase comprising greater than about 50 weight percent methyl iodide. In embodiments, the distillation zone comprises a plurality of internal components, each having a component liquid retention volume, wherein each of the internal components is dimensioned and arranged such that an average residence time of the first liquid phase and an average residence time of the second liquid phase in each of the component liquid retention volumes is less than about 30 minutes.

In embodiments, at least one internal component is dimensioned and arranged such that the average residence time of the first liquid phase is greater than or equal to the average residence time of the second liquid phase in the corresponding component liquid retention volume. In embodiments, at least one internal component comprises a first plurality of flow paths dimensioned and arranged such that the average residence time of the first liquid phase is from about 0.1 minutes to about 20 minutes in the corresponding component liquid retention volume, and/or at least one internal component further comprises a second plurality of flow paths dimensioned and arranged such that the average residence time of the second liquid phase is from about 0.1 minutes to about 20 minutes in the corresponding component liquid retention volume.

In embodiments, a bottom temperature of the second distillation column is about 90° C. to about 130° C.; a pressure of the second distillation column is from atmospheric pressure to about 700 kPa above atmospheric pressure, or a combination thereof. The process of claim 8, wherein the second column feed stream comprises at least 10 wt % of the light phase and at least 10 wt % of the heavy phase, based on the total amount of the second column feed stream.

In embodiments the process may further comprise introducing a lithium compound selected from the group consisting of lithium acetate, lithium carboxylates, lithium carbonates, lithium hydroxide, and mixtures thereof into the reaction medium to maintain the concentration of lithium acetate between 0.3 and 0.7 wt % in the reaction medium.

In embodiments the process may further comprise maintaining the concentration of hydrogen iodide from 0.1 to 1.3 wt % in the reactor; maintaining the concentration of the rhodium catalyst from 300 to 3000 wppm in the reaction medium, based on the total weight of the reaction medium; maintaining the concentration of water from 0.1 to 4.1 wt % in the reaction medium; maintaining the concentration of methyl acetate from 0.6 to 4.1 wt % in the reaction medium; or a combination thereof.

In embodiments the process may further comprise controlling a butyl acetate concentration in the acetic acid product stream at 10 wppm or less without directly removing butyl acetate from the acetic acid product steam, wherein the butyl acetate concentration is controlled by maintaining an acetaldehyde concentration in the reaction medium at 1500 ppm or less, controlling a temperature in the reactor from 150 to 250° C., controlling a hydrogen partial pressure in the carbonylation reactor from 0.3 to 2 atm, controlling a rhodium metal catalyst concentration in the reaction medium from 100 to 3000 wppm, based on the total weight of the reaction medium, or a combination thereof.

In embodiments the process may further comprise controlling an ethyl iodide concentration in the reaction medium at less than or equal to 750 wppm, wherein the acetic acid product stream comprises less than 250 wppm propionic acid without directly removing propionic acid from the acetic acid product stream. In embodiments, the ethyl iodide in the reaction medium and propionic acid in the acetic acid product stream are present in a weight ratio from 3:1 to 1:2; the acetaldehyde and ethyl iodide are present in the reaction medium in a weight ratio from 2:1 to 20:1; the methanol introduced into the reactor comprises less than 150 wppm ethanol; the ethyl iodide concentration in the reaction medium is controlled by adjusting a hydrogen partial pressure in the reactor, a methyl acetate concentration in the reaction medium, a methyl iodide concentration in the reaction medium; or a combination thereof.

Acetic Acid Production System

Processes to produce acetic acid via methanol carbonylation can be conveniently divided into three main areas: the reaction systems, the internal purification systems, and the product purification systems.

The reaction systems include the carbonylation reactor, the flasher, and the like. The internal purification systems include the light ends recovery/acetic acid product separation systems, aldehyde removal systems, and the like.

The product purification systems include drying columns, resin beds, and the like, directed to purifying the acetic acid to produce the final product.

Examples of processes suitable to produce the distillation column feed stream according to the instant disclosure include those described in U.S. Pat. No. 3,769,329; U.S. Pat. No. 3,772,156; U.S. Pat. No. 4,039,395; U.S. Pat. No. 4,255,591; U.S. Pat. No. 4,615,806; U.S. Pat. No. 5,001,259; U.S. Pat. No. 5,026,908; U.S. Pat. No. 5,144,068; U.S. Pat. No. 5,237,097; U.S. Pat. No. 5,334,755; U.S. Pat. No. 5,625,095; U.S. Pat. No. 5,653,853; U.S. Pat. No. 5,683,492; U.S. Pat. No. 5,831,120, U.S. Pat. No. 5,227,520; U.S. Pat. No. 5,416,237, U.S. Pat. No. 5,731,252; U.S. Pat. No. 5,916,422; U.S. Pat. No. 6,143,930; U.S. Pat. No. 6,225,498, U.S. Pat. No. 6,255,527; U.S. Pat. No. 6,339,171; U.S. Pat. No. 6,657,078; U.S. Pat. No. 7,208,624; U.S. Pat. No. 7,223,883; U.S. Pat. No. 7,223,886; U.S. Pat. No. 7,271,293; U.S. Pat. No. 7,476,761; U.S. Pat. No. 7,838,701; U.S. Pat. No. 7,855,306; U.S. Pat. No. 8,076,507; US20060247466; US20090036710; US20090259072; US20090062525; US20110288333; US20120090981; US20120078012; US20130116470; US20130261334; US20130264186; US20130281735; US20130261334; US20130281735; EP0161874; WO9822420; WO0216297; WO2013137236, and the like, the entire contents and disclosure of which are hereby incorporated by reference.

Reaction Systems and Processes

As shown in FIG. 1, the processes 100 includes directing a methanol-containing feed stream 101 and a carbon monoxide-containing feed stream 102 into a liquid phase reaction medium 105 of a carbonylation reactor 104, wherein they are contacted in the presence of catalyst, water, methyl iodide, methyl acetate, acetic acid, an iodide salt, and other reaction medium components to produce acetic acid.

A portion of the reaction medium 105 is continuously removed from the reactor 104 to the flasher 112 via line 113. This stream is subject to flash or low pressure distillation in flasher 112, wherein acetic acid and other volatile components are separated from the non-volatile components present in the reaction medium. The non-volatile components are recycled back into the reaction medium via stream 110. The volatile components of the reaction medium are directed overhead via line 122 into the light ends column 124.

As the figure shows, the process includes a number of recycle lines through which various streams are recycled back into the reaction medium from other parts of the process. The process also includes various vapor purge lines, and the like. It is to be understood that all vents and other vapor lines are connected to one or more scrubber or vent systems and that all condensable components discharged to the scrubber system are eventually recycled back into the carbonylation reactor.

In embodiments, the reaction medium comprises a metal catalyst, or a Group VIII metal catalyst, or a catalyst comprising rhodium, nickel and/or iridium. In embodiments, the reaction medium comprises a rhodium catalyst, typically from about 200 to about 5000 parts per million (ppm) by weight, based on the total weight of the reaction medium.

In embodiments, the reaction medium further comprises a halogen-containing catalyst promoter, typically methyl iodide (MeI). In embodiments, the reaction medium comprises greater than or equal to about 5 weight percent Ma or from about 5 weight percent to about 50 weight percent MeI. In embodiments, the reaction medium comprises greater than or equal to about 50 weight percent AcOH.

In embodiments, the reaction medium comprises a finite concentration of water. In so-called low-water processes, the reaction medium comprises a finite concentration of water up to about 14 wt %.

In embodiments, the reaction medium has a finite water concentration. In embodiments, the water concentration in the reaction medium is greater than or equal to 0.1 wt %, or 0.5 wt %, or 1 wt %, or 2 wt %, or 3.5 wt %, or 4 wt %, or 5 wt %, and less than or equal to 10 wt %, 7 wt %, or 6 wt %. In embodiments, the reactor water concentration is from 0.1 to 5 wt %, or 0.2 to 4 wt %, or 1 to 3 wt %, based on the total amount of the reaction medium present.

In embodiments, the reaction medium further comprises from about 0.5 weight percent to less than 20 weight percent methyl acetate (MeAc).

In embodiments, the reaction medium further comprises hydrogen iodide and one or more iodide salts, typically lithium iodide (LiI), in an amount sufficient to produce a total iodide ion concentration greater than or equal to about 2 weight percent and less than or equal to about 30 weight percent of the reaction medium.

In embodiments, the reaction medium may further comprise hydrogen, determined according to a hydrogen partial pressure present in the reactor. In embodiments, the partial pressure of hydrogen in the reactor is greater than or equal to about 0.7 kPa (0.1 psia), or 3.5 kPa (0.5 psia), or 6.9 kPa (1 psia), and less than or equal to about 1.03 MPa (150 psia), or 689 kPa (100 psia), or 345 kPa (50 psia), or 138 kPa (20 psia).

In embodiments, the reactor temperature i.e., the temperature of the reaction medium, is greater than or equal to about 150° C. In embodiments, the reactor temperature is greater than or equal to about 150° C. and less than or equal to about 250° C. In embodiments, the reactor temperature is greater than or equal to about 180° and less than or equal to about 220° C.

In embodiments, the carbon monoxide partial pressure in the reactor is greater than or equal to about 200 kPa. In embodiments, the CO partial pressure is greater than or equal to about 200 kPa and less than or equal to about 3 MPa. In embodiments, the CO partial pressure in the reactor is greater than or equal to about the 300 kPa, or 400 kPa, or 500 kPa and less than or equal to about 2 MPa, or 1 MPa. The total reactor pressure represents the combined partial pressure of all reactants, products, and by-products present therein. In embodiments, the total reactor pressure is greater than or equal to about 1 MPa and less than or equal to about 4 MPa.

In an embodiment, vapor product stream 122 from flasher 112 comprises acetic acid, methyl iodide, methyl acetate, water and acetaldehyde. In one embodiment, vapor product stream 122 comprises acetic acid in an amount from 45 to 75 wt. %, methyl iodide in an amount from 20 to 50 wt. %, methyl acetate in an amount of less than or equal to 9 wt. %, and water in an amount of less than or equal to 15 wt. %, based on the total weight of the vapor product stream. In another embodiment, vapor product stream 122 comprises acetic acid in an amount from 45 to 75 wt. %, methyl iodide in an amount from 24 to less than 36 wt. %, methyl acetate in an amount of less than or equal to 9 wt. %, and water in an amount of less than or equal to 15 wt. %, based on the total weight of the vapor product stream. In embodiments, vapor product stream 122 comprises acetic acid in an amount from 55 to 75 wt. %, methyl iodide in an amount from 24 to 35 wt. %, methyl acetate in an amount from 0.5 to 8 wt. %, and water in an amount from 0.5 to 14 wt. %. In still other embodiments, vapor product stream 122 comprises acetic acid in an amount from 60 to 70 wt. %, methyl iodide in an amount from 25 to 35 wt. %, methyl acetate in an amount from 0.5 to 6.5 wt. %, and water in an amount from 1 to 8 wt. %. The acetaldehyde concentration in the vapor product stream may be in an amount from 0.005 to 1 wt. %, based on the total weight of the vapor product stream, e.g., from 0.01 to 0.8 wt. %, or from 0.01 to 0.7 wt. %. In some embodiments the acetaldehyde may be present in amounts less than or equal to 0.01 wt. %. Vapor product stream 122 may comprise hydrogen iodide in an amount less than or equal to 1 wt. %, based on the total weight of the vapor product stream, or less than or equal to 0.5 wt. %, or less than or equal to 0.1 wt. %. Vapor product stream 122 may be substantially free of, i.e., contains less than or equal to 0.0001 wt. %, propionic acid, based on the total weight of the vapor product stream.

Liquid recycle stream 110 comprises acetic acid, the metal catalyst, corrosion metals, as well as other various compounds. In an embodiment, liquid recycle stream 110 comprises acetic acid in an amount from 60 to 90 wt. %, metal catalyst in an amount from 0.01 to 0.5 wt. %; corrosion metals (e.g., nickel, iron and chromium) in a total amount from 10 to 2500 wppm; lithium iodide in an amount from 5 to 20 wt. %; methyl iodide in an amount from 0.5 to 5 wt. %; methyl acetate in an amount from 0.1 to 5 wt. %; water in an amount from 0.1 to 8 wt. %; acetaldehyde in an amount of less than or equal to 1 wt. % (e.g., from 0.0001 to 1 wt. % acetaldehyde); and hydrogen iodide in an amount of less than or equal to 0.5 wt. % (e.g., from 0.0001 to 0.5 wt. % hydrogen iodide).

Light Ends Recovery/Acetic Acid Product Separation Systems and Processes

In embodiments, the overhead stream from flasher 112 is directed as stream 122 to a first distillation column 124, which may also be referred to as the light ends column or the stripper column. Accordingly, the feed stream to the first distillation column is derived from the reaction medium because it undergoes distillation prior to entering the first distillation column. Distillation of the feed stream in the light ends column 124 yields a low-boiling first overhead vapor stream 126, referred to herein as the first overhead stream 126, and a purified acetic acid stream 128. Stream 128 is a crude acetic acid stream, which is subsequently purified. In embodiments, acetic acid stream 128 is removed as a side stream. The light ends column 124 further produces a high boiling residuum stream 116, which may be subject to further purification and/or may be recycled back into the reaction medium.

Each distillation column utilized in the process may be a conventional distillation column, e.g., a plate column, a packed column, and others. Plate columns may include a perforated plate column, bubble-cap column, Kittel tray column, uniflux tray, or a ripple tray column. The material of the distillation column is not limited and may include a glass, a metal, a ceramic, or other suitable material can be used. For a plate column, the theoretical number of plates is not particularly limited and depending on the species of the component to be separate, may depend on the component to be separated. In embodiments, the column may include up to 80 plates, e.g., from 2 to 80, from 5 to 60, from 5 to 50, or more preferably from 7 to 35. The distillation column may include a combination of different distillation apparatuses. For example, a combination of bubble-cap column and perforated plate column may be used as well as a combination of perforated plate column and a packed column.

The distillation temperature and pressure in the distillation system can suitably be selected depending on the condition such as the species of the objective carboxylic acid and the species of the distillation column, or the removal target selected from the lower boiling point impurity and the higher boiling point impurity according to the composition of the feed stream. For example, in a case where the purification of acetic acid is carried out by the distillation column, the inner pressure of the distillation column (usually, the pressure of the column top) may be from 0.01 to 1 MPa, e.g., from 0.02 to 0.7 MPa, and more preferably from 0.05 to 0.5 MPa in terms of gauge pressure. Moreover, the distillation temperature for the distillation column, namely the inner temperature of the column at the temperature of the column top, can be controlled by adjusting the inner pressure of the column, and, for example, may be from 20 to 200° C., e.g., from 50 to 180° C., and more preferably about 100 to 160° C.

The material of each member or unit associated with the distillation system, including the columns, valves, condensers, receivers, pumps, reboilers, and internals, and various lines, each communicating to the distillation system may be suitable material such as glass, metal, ceramic, or combinations thereof, and is not particularly limited to a specific one. In embodiments, the material of the foregoing distillation system and various lines are a transition metal or a transition-metal-based alloy such as iron alloy, e.g., a stainless steel, nickel or nickel alloy, zirconium or zirconium alloy thereof, titanium or titanium alloy thereof, or aluminum alloy. Suitable iron-based alloy include any alloy containing iron as a main component, e.g., a stainless steel that also comprises chromium, nickel, molybdenum and others. Suitable a nickel-based alloy include containing nickel as a main component and one or more of chromium, iron, cobalt, molybdenum, tungsten, manganese, and others, e.g., HASTELLOY™ and INCONEL™ Corrosion-resistant metals may be particularly suitable as materials for the distillation system and various lines.

In embodiments, acetic acid stream 128 is subjected to further purification in the product purification section of the process, such as in a drying column 130 to remove water to produce a final product acetic acid stream. In embodiments, the acetic acid stream 128 may be further purified in a heavy ends column (cf. WO0216297), and/or contacted with one or more absorbent, adsorbent, or purification resins in guard column 200 to remove various impurities (cf. U.S. Pat. No. 6,657,078) to produce a purified product acetic acid stream, indicated in FIG. 1 as the purified product.

In embodiments, the first overhead 126 is condensed and then directed into an overhead phase separation unit 134, (overhead decanter 134). The first overhead 126 comprises methyl iodide, methyl acetate, acetic acid, water, and at least one PRC. In embodiments, the condensed first overhead stream 126 is separated into a light aqueous phase 135 comprising water, acetic acid, methyl iodide, methyl acetate, and at least one PRC; and a heavy phase 137 comprising methyl iodide, methyl acetate, and at least one PRC. In view of the solubility of methyl iodide in water and vice-versa, the heavy phase 137 comprises some water and the light phase 135 comprises some methyl iodide.

The exact compositions of these two streams are a function of the methyl acetate, acetic acid, acetaldehyde, and other components which are also present in the light ends overhead stream 126. Although the specific compositions of light liquid phase 135 may vary widely, some exemplary compositions are provided below in Table 1.

TABLE 1 Exemplary Light Liquid Phase from Light Ends Overhead Component conc. (Wt. %) conc. (Wt. %) conc. (Wt. %) Water 40-80  50-75  70-75  Methyl Acetate 1-50 1-25 1-15 Acetic Acid 1-40 1-25 5-15 PRC's  <5 <3 <1 Methyl Iodide <10 <5 <3

In an embodiment, overhead decanter 134 is arranged and constructed to maintain a low interface level to prevent an excess hold up of methyl iodide. Although the specific compositions of heavy liquid phase 137 may vary widely, some exemplary compositions are provided below in Table 2.

TABLE 2 Exemplary Heavy Liquid Phase from Light Ends Overhead Component conc. (Wt. %) conc. (Wt. %) conc. (Wt. %) Water 0.01-2  0.05-1  0.1-0.9 Methyl Acetate 0.1-25 0.5-20 0.7-15  Acetic Acid 0.1-10 0.2-8  0.5-6  PRC's <5 <3 <1 Methyl Iodide  40-98  50-95 60-85

In embodiments, at least a portion of the heavy phase 137, the light phase 135, or both is returned to the reaction medium via line 114. In embodiments, essentially all of the heavy phase 137 is recirculated to the reactor and the light phase 135 is forwarded to the aldehyde removal process 108. In alternative embodiments, essentially all of the light phase 135 is recirculated to the reactor and the heavy phase 137 is forwarded to the aldehyde removal process 108. For purposes herein, examples are directed to forwarding the light phase 135 to the aldehyde removal process 108. It is to be understood, however, that the heavy phase 137 alone, or in combination with the light phase 135 may be forwarded to the aldehyde removal process 108. In embodiments, a portion of the heavy phase 137, typically from about 5 to 40 volume percent may be directed to the aldehyde removal system 108 and the remainder recycled to the reaction medium. In embodiments, at least a portion of the condensed second column overhead 138 is directed back into the light ends column 124 as reflux via stream 140.

In embodiments, a stream derived from the first column overhead 126, i.e. the light phase 135, the heavy phase 137, or a combination of the two streams is provided as a feed stream 142 to the aldehyde removal system 108, (the ARS). The feed stream 142 comprises methyl iodide, water, acetic acid, methyl acetate, and at least one PRC.

In embodiments, the feed stream 142 comprises at least 10 wt % light phase 135, or 20 wt % light phase 135, or 30 wt % light phase 135, or 40 wt % light phase 135, or 50 wt % light phase 135, or 60 wt % light phase 135, or 70 wt % light phase 135, or 80 wt % light phase 135, or 90 wt % light phase 135, or consists essentially of light phase 135, and/or feed stream 142 comprises at least 10 wt % heavy phase 137, or 20 wt % heavy phase 137, or 30 wt % heavy phase 137, or 40 wt % heavy phase 137, or 50 wt % heavy phase 137, or 60 wt % heavy phase 137, or 70 wt % heavy phase 137, or 80 wt % heavy phase 137 or 90 wt % heavy phase 137, or consists essentially of heavy phase 137.

In embodiments, the second column feed stream 142 comprises from 10 wt % to 90 wt % of the light phase 135, and from 10 wt % to 90 wt % of the heavy phase 137, based on the total amount of the first column overhead stream 126 present in the second column feed stream 142. Accordingly, feed stream 142 comprises at least a portion of the first column overhead 126, and the total amount of the this first column overhead stream 126 present in feed stream 142 consists of a X % light phase 135 and Y % heavy phase 137, wherein X %+Y %=100%. For the purposes of this calculation it is to be understood that feed stream 142 may comprise additional components and/or streams other than the relative proportions of stream 126.

In embodiments, the aldehyde removal system comprises at least one distillation column 150. The distillation column 150 comprising a distillation zone 312 and a bottom sump zone 314 (cf. FIG. 3).

As shown in FIG. 1, the aldehyde removal system 108 may comprise a single distillation column 150. In FIG. 1, the single distillation column ARS embodiment is generally indicated as 132. In this embodiment, the ARS feed stream 142 is distilled in the second distillation column 150 to remove water, acetic acid methyl iodide and methyl acetate from the residuum 154, and to form a second overhead stream 152 comprising the PRC's (acetaldehyde) concentrated in methyl iodide.

As shown in FIG. 2, in alternative embodiments, the aldehyde removal system 108 may comprise at least two distillation columns 170 and 172. This multi-column ARS is generally indicated as 133. In assembly 133, the feed stream 142 is directed into a separation column 170 to remove water and acetic acid as residuum stream 174. The overhead 178 comprises methyl iodide, methyl acetate, and the PRC's. A portion of the overhead 178 may be refluxed back into the separation column as stream 181.

Overhead stream 178 is then directed into the second distillation column 172 as stream 179. Stream 179 is referred to herein as the alternative second column feed stream 179. The feed stream 179 is distilled in the second distillation column 172 to produce the second overhead stream 152 comprising methyl iodide and at least one PRC. Distillation of the alternative second column feed stream 179 further produces residuum stream 154 flowing from the bottom sump zone of column 172 comprising water and greater than or equal to about 0.11 weight percent HI.

Both of these ARS systems are described herein using similar descriptions with like indicators used to describe streams which are essentially identical in each system. The second column overhead 152 and the second column residuum 154 produced using assembly 132 are essentially identical to the same streams 152 and 154 produced using assembly 133. Accordingly, for purposes herein, various flow rates, directing of various streams, and the like are referred to interchangeably between the assemblies shown in 132 and 133. In embodiments, second overhead stream 152 may further comprise dimethyl ether. In embodiments, the process may be operated such that DME is formed in-situ, within the second distillation column 150 or 172. In embodiments in which DME is intentionally formed within the process, DME is known to accumulate in the second column overhead 152, the overhead accumulation tank 160, and the rest of the ARS system.

In embodiments, the second column overhead 152 is condensed and forwarded to an overhead separator 160. A portion of the condensed second column overhead 162 may be refluxed back into the second distillation column (150 or 172) via lines 167 and 164. At least a portion of the condensed second column overhead 162 is cooled (e.g., via heat exchanger 173), and contacted with an aqueous stream 166 (typically water) in at least one extractor 169, typically at an extraction temperature below about 25° C., or below about 20° C., or below 15° C., or below about 10° C., or below about 5° C. However, in embodiments, the extraction temperature may be from 50° C. to 30° C. Extraction of the second column overhead 152 produces an aqueous waste stream 168 comprising PRC and a small amount of methyl iodide which is subsequently removed from the process as waste. The extraction also produces the raffinate stream 158, which comprises methyl iodide. When the second column overhead 152 comprises dimethyl ether, the raffinate stream 158 also comprises dimethyl ether.

In an embodiment, at least a portion of the raffinate stream 158 is recycled back into the second distillation column via line 161, which greatly improves the amount of PRC's present in the second column overhead 152.

In embodiments, the raffinate stream 158 is divided into two portions: a first portion 161 and a second portion 163. The first portion of the raffinate stream flow 161 is recycled back into the second distillation column. The second portion of the raffinate stream flow 163 is recycled back into the reaction medium via stream 155, e.g., via combining stream 155 with stream 116, 118, and/or the like. The recycle of a portion of the raffinate stream back into the reaction medium consumes the DME present in the stream. This prevents excessive accumulation of the DME in the second distillation column 150 or 172, thereby preventing overpressure of the second distillation column 150 or 172 (cf. U.S. Pat. No. 7,223,883). Pressure buildup in column 150 or 172 causes venting of the overhead separator 160 to the scrubber system 139. This venting results in the undesirable recycle of acetaldehyde back into the reaction medium.

In embodiments, a mass flow of the first portion of the raffinate 161 is greater than or equal to a mass flow of the second portion of the raffinate 163. In embodiments, the mass flow of the first portion of the raffinate 161 is greater than or equal to about 1%, or 5%, or 10%, or 20%, or 30%, or 40%, or 50%, or 60%, or 70%, or 80%, or 90%, and less than 500% of the mass flow of the second portion of the raffinate 163. In embodiments, the mass flow of the second portion of the raffinate 163 is greater than or equal to about 1%, or 5%, or 10%, or 20%, or 30%, or 40%, or 50%, or 60%, or 70%, or 80%, or 90%, and less than 500% of the mass flow of the first portion of the raffinate 161.

In embodiments, second distillation column (150 or 172) may optionally comprise a sidestream 157 from which a stream comprising methyl acetate is produced. The optional sidestream 157 allows the second distillation column to be operated under conditions desirable for obtaining a higher concentration of acetaldehyde in the second column overhead stream 152 while providing a mechanism for removing methyl acetate and/or methanol that might otherwise accumulate in the center of the second distillation column (e.g., a methyl acetate bulge) which is eventually pushed into the second column overhead stream 152. The optional sidestream 157, comprising methyl acetate, if utilized, is preferably recycled back into the process.

Embodiments of the instant process may further comprise directing a top flush stream 164 comprising water into the distillation zone of the second distillation column 150 or 172. The top flush stream 164 may comprise fresh material, but is preferably generated from a stream produced by the process to control water content in the system. In embodiments, the top flush stream 164 comprises water, acetic acid, methanol, or any combination thereof.

In embodiments utilizing assembly 133, a portion of the separation column residuum stream 174 may be directed via stream 156 and 164 into the alternative second distillation column 172 as the top flush stream 164. In embodiments in which apparatus 132 is utilized, the top flush stream may include at least a portion of residuum stream 154, directed via stream 156 to 164. In embodiments, top flush stream 164 may include a portion of the light phase overhead stream 135.

In embodiments, the mass flow rate of the top flush stream 164 is greater than or equal to about 1% of the total mass flow rate of feed stream 142, the second column feed stream 143, or feed stream 179 where applicable. In embodiments, the mass flow rate of the top flush stream 164 is greater than or equal to about 5%, or 10%, or 20%, or 30%, or 40%, or 50%, or 60%, or 70%, or 80%, or 90%, 100%, or 150%, and less than 500% of the mass flow of feed stream 142, the second column feed stream 143, or feed stream 179 where applicable.

In an embodiment, the process may further comprise directing a bottom flush stream 165 into the distillation zone of the second distillation column and/or into the bottom sump zone of the second distillation column. The bottom flush stream 165 may comprise, water, acetic acid, or both. In embodiments, bottom flush stream 165 comprises at least 10 wt %, or 20 wt %, or 30 wt %, or 40 wt %, or 50 wt %, or 60 wt %, or 70 wt %, or 80 wt %, or 90 wt %, or 95 wt % acetic acid. In embodiments, the bottom flush stream consists of, or consists essentially of acetic acid.

In embodiments, the mass flow rate of the bottom flush stream 165 into the second distillation column 150 or 172 is greater than or equal to about 0.1% of the total mass flow rate of feed stream 142, or the second column feed stream 143 or 179. In embodiments, the mass flow rate of the bottom flush stream 165 is greater than or equal to about 5%, or 10%, or 20%, or 30%, or 40%, or 50%, or 60%, or 70%, or 80%, or 90%, 100%, or 150%, or 200%, or 300%, and less than 500% of the mass flow of feed stream 142, the second column feed stream 143, or feed stream 179 where applicable.

In embodiments, the total combined mass flow rates of the top flush stream 164 and the bottom flush stream 165 is about 1.1%, or 5%, or 10%, or 20%, or 30%, or 40%, or 50%, or 60%, or 70%, or 80%, or 90%, 100%, or 150%, or 200%, or 300%, and less than 500% of the mass flow of feed stream 142, the second column feed stream 143, or feed stream 179 where applicable.

In embodiments, the mass flow rate of the top flush stream 164, the mass flow rate of the bottom flush stream 165, or the total combined mass flow rates of the top flush stream 164 and the bottom flush stream 165 is from about 1% to about 50% of the mass flow rate of the residuum stream 154.

In embodiments, second distillation column residuum stream 154 comprises water, acetic acid, and at least about 0.11 weight percent HI. In embodiments, residuum stream 154 comprises greater than or equal to about 5 wt % water, or 10 wt %, or 20 wt %, or 30 wt %, or 40 wt %, or 50 wt %, or 60 wt %, or 70 wt %, or 80 wt %, or 90 wt %, or 95 wt % water. In embodiments, residuum stream 154 comprises greater than or equal to about 5 weight percent acetic acid, or 10 wt %, or 20 wt %, or 30 wt %, or 40 wt %, or 50 wt %, or 60 wt %, or 70 wt %, or 80 wt %, or 90 wt %, or 95 wt % acetic acid. In embodiments, residuum stream 154 comprises greater than or equal to about 5 wt % methyl iodide, or 10 wt %, or 20 wt %, or 30 wt %, or 40 wt %, or 50 wt %, or 60 wt %, or 70 wt %, or 80 wt %, or 90 wt %, or 95 wt % methyl iodide.

In embodiments, the second column residuum stream 154 comprises greater than or equal to about 0.11 weight percent HI. In an embodiment, the residuum stream 154 comprises greater than or equal to about 0.21 weight percent HI, or greater than or equal to about 0.25 weight percent HI, or greater than or equal to about 0.3 weight percent HI, or greater than or equal to about 0.35 weight percent HI, or greater than or equal to about 0.4 weight percent HI, or greater than or equal to about 0.5 weight percent HI, or greater than or equal to about 0.6 weight percent HI, or greater than or equal to about 0.65 weight percent HI, or greater than or equal to about 0.7 weight percent HI.

In embodiments, HI is produced within the second distillation column, typically through the hydrolysis of methyl iodide into methanol and HI such that a total amount of HI exiting the distillation column in the overhead stream (if any) and the residuum stream is greater than an amount of HI entering the distillation column (if any), in the feed stream. The term “if any” denotes that HI is not necessarily present in the column feed stream, but may be. Accordingly, more HI exits the distillation column (150 or 172) via overhead stream 152 and/or residuum stream 154 than enters the column in the column feed stream 142. Corrosion considerations render excessive amounts of HI generally undesirable. As discussed above, a certain amount of HI, controlled within a specific range, is desirable in order to catalyze the formation of a controlled amount of DME within the column. This DME has been found to have a beneficial effect on phase separation in the liquid-liquid extraction system common to acetaldehyde removal systems as exemplified in U.S. Pat. No. 7,223,883, U.S. Pat. No. 7,223,886, and U.S. Pat. No. 8,076,507. In embodiments, the residuum stream 154 comprises less than or equal to about 10 weight percent HI, or less than or equal to about 5 weight percent HI, or less than or equal to about 2 weight percent HI, or less than or equal to about 1.5 weight percent HI, or less than or equal to about 1.2 weight percent HI, or less than or equal to about 1.1 weight percent HI, or less than or equal to about 1.0 weight percent HI, or less than or equal to about 0.9 weight percent HI, or 0.75 weight percent HI, or less than or equal to about 0.7 weight percent HI, or less than or equal to about 0.65 weight percent HI, or less than or equal to about 0.6 weight percent HI, or less than or equal to about 0.55 weight percent HI, or less than or equal to about 0.5 weight percent HI, or less than or equal to about 0.45 weight percent HI, based on the total weight of the residuum stream. The maximum concentration of HI in the second column residuum stream 154 may be selected according to an acceptable level of corrosion under the conditions present therein. Accordingly, selection of particular materials may allow for even higher concentrations of HI in the residuum above 0.11 wt %.

In embodiments, residuum stream 154 may further comprise methyl iodide, methanol, methyl acetate, and/or acetaldehyde. In embodiments, a portion of residuum stream 154 may be directed to drying column 130, e.g. via reflux derived from drying column decanter 148, to the reactor 104, or both.

As shown in FIG. 3, in an embodiment, the second distillation column (FIG. 3 shows column 150 which for purposes of the figures is representative of either 150 or 172) comprises a distillation zone 312 and a bottom sump zone 314. The distillation zone 312 is everything above the bottom sump zone 314, and may comprise various internal components including, but not limited to packing sections, liquid collectors/redistributors, trays, supports, and the like.

In embodiments, the second distillation column contains at least 100 trays and is operated at a temperature ranging from about 101° C. at the bottom to about 60° C. at the top. In an alternative embodiment, the second distillation column comprises structured packing in place of trays. In embodiments, the structured packing, a random packing, or a combination thereof, having an interfacial area of 150 to 400 m²/m³, and may comprise ceramic, polymeric, an austenitic-ferritic metallic alloy, or a combination thereof. In embodiments, a bottom temperature of the second distillation column is from about 90° C. to about 130° C., a pressure of the second distillation column is from atmospheric pressure or about 150 kPa above atmospheric pressure, to about 700 kPa above atmospheric pressure, or a combination thereof.

In embodiments, the distillation zone is dimensioned and arranged to control the contact time between methyl iodide and water to control the concentration of HI in the second distillation column residuum 154.

In embodiments, the liquid phase present within the second distillation column comprises a first liquid phase comprising greater than about 50 weight percent water (an aqueous or water phase) and a second liquid phase comprising greater than about 50 weight percent methyl iodide (a methyl iodide phase).

In embodiments, the distillation zone 312, and in particular various internal components within the distillation zone, are dimensioned and arranged to control the contact time between the methyl iodide phase and the water phase to the minimum amount required to produce a second column residuum stream 154 having an HI concentration greater than or equal to about 0.11 weight percent.

In embodiments, the internal components are designed (dimensioned and arranged) to minimize the residence time of the liquid phases present within the distillation column under process conditions. It has been discovered that a minimum contact time between the aqueous phase and the methyl iodide phase within the second distillation column is necessary to produce a residuum stream flowing from the bottom sump zone comprising water and greater than or equal to about 0.11 weight percent HI. In embodiments, a total amount of HI exiting the distillation column in the overhead stream and the residuum stream is greater than an amount of HI entering the distillation column, if any, in the feed stream. However, it has also been discovered that prolonged contact time between discrete portions of the aqueous phase and the methyl iodide phase adversely affect the ability to control the amount of HI in the residuum stream. Such prolonged contact time may result from pooling and/or trapping of discrete portions of a particular phase within particular internal components of the column, without affecting the overall residence time of the liquid phase within the distillation column.

As shown in FIG. 3, in embodiments, the second distillation column 150 or 172 may comprises a plurality of internal components which may include liquid collectors 310, liquid distributors 300, and the like, which may be dispersed between a plurality of packing sections 302 and 304 each individually comprising structured packing, random packing, or a combination thereof. In alternative embodiments, the internal components may be distillation plates or trays, along with various supports 308 and collectors.

In embodiments, the distillation zone 312 comprises a vapor phase and a liquid phase, the liquid phase comprising a first liquid phase 326 (cf. FIG. 4) and a second liquid phase 328 (cf. FIG. 4), wherein the first liquid phase comprises greater than about 50 weight percent water and the second liquid phase comprises greater than about 50 weight percent methyl iodide. Apart from some intra-solubility, the two liquid phases are generally immiscible.

As shown in FIG. 4, each internal component includes an associated or corresponding liquid phase retention volume which is dependent on the dimensions and arrangement of the component. In embodiments in which two liquid phases are present within the distillation column, the total retention volume of the liquid phase associated with a particular component is equal to the sum of the retention volume of the first liquid phase 326 and the retention volume of the second liquid phase 328 within the confines of the particular component. The liquid holdup volume of the distillation zone is thus equal to the sum of each of the liquid phase retention volumes of the components within the distillation zone plus the amount present on the sides and other non-functional surfaces of the column.

Each component retention volume has a corresponding residence time of the first liquid phase and a corresponding residence time of the second liquid phase under operational conditions. The residence time of a particular liquid phase in an internal component is equal to the average time a discrete amount of that particular liquid phase is retained within the component's retention volume under operational conditions. However, the physical properties of the two liquid phases, the position of drains or flow paths of the internal component, and/or other aspects of the internal component may result in pooling or trapping of one of the liquid phases within its retention volume. A liquid phase which becomes trapped within the retention volume of a particular component may have an average residence time within that particular component which exceeds the average residence time of the entire liquid phase in the distillation zone of the column.

Accordingly, the residence times of particular liquid phases within the internal components of a distillation column must be measured directly or calculated/and or modeled under operational conditions based on the physical properties of the liquid phases and the design and arrangement of the particular components.

As shown in FIG. 4 since two liquid phases 326 and 328 are present during the distillation, column internals which do not include bottom drains, or which do not comprise adequately sized or positioned bottom drains will tend to accumulate the heavier methyl iodide second liquid phase 328 beneath the lighter aqueous first liquid phase 326, even though the methyl iodide phase has a lower boiling point than the aqueous phase. The heavier methyl iodide phase will then tend to progress through the column when carried along with the lighter aqueous phase. The heavier phase may also accumulate in a retention volume and then overflow the various structures within the column. Such column designs result in prolonged and unpredictable residence times for discrete portions of the second liquid phase.

Likewise, as show in FIG. 4, column internals which include bottom drains but which do not include top drains, or which do not comprise adequately sized or positioned top drains will tend to accumulate the lighter aqueous first liquid phase 326 within the retention volume of the internal component. The first liquid phase 326 may then become trapped relative to the better drained heavier second liquid phase 328, which drains through the accumulated first liquid phase 326 and through one or more bottom drain holes 340. The lighter first liquid phase will then tend to progress through the column only when carried along with the heavy phase, or by overflowing the various structures within the column, leading to prolonged residence times for discrete portions of the first aqueous liquid phase within the retention volume of certain internal component structures.

As shown in FIG. 4, in an embodiment, a liquid redistributor, tray, or other column internal 300 may include one or more vapor risers 316 which allow the vapor phase to flow through the structure, and one or more drip tubes 318 to allow liquid to pass through the structure from one side to another. In an embodiment, one or more drip tubes 318 may each comprise at least one of a first plurality of passages 324, disposed there-through which are holes arranged to drain the first liquid phase 326, which is less dense (lighter) than the second liquid phase 328, and thus located farther away from bottom of the structure. Each drip tube 318 may further comprises at least one of a second plurality of passages 330 disposed there-through, which are holes arranged proximate to the bottom of the structure to drain the second heavier liquid phase 328 there-through.

FIG. 5 shows an embodiment wherein each of the drip tubes 320 comprise at least one of the first plurality of passages which are combined with the second plurality of passages in the form of a slit 332 disposed there through along a vertical wall of the drip tube 320 which allows both the first light phase 326 and the second heavy phase 328 to drain through the structure.

FIG. 6 shows an embodiment wherein each of the drip tubes 322 comprise at least one of the first plurality of passages in the form of a slit 334 disposed there through along only a portion of a vertical wall of the drip tube 322, which is arranged to allow the first light phase 326 to drain through the structure, and each drip tube 322 may further comprises at least one of a second plurality of passages 336 disposed there-through, which are holes arranged proximate to the bottom of the structure to drain the second heavier liquid phase 328 there through.

In embodiments, as shown in FIG. 4, a structure may comprise a weir or dam having a side height 338 (e.g., a side of a liquid redistributor 300 or a column tray) which allows the lighter first phase 326 to drain by spilling over the side, in combination with the tray being equipped with one or more bottom drain holes 340 to allow the heavy phase to drain there-through.

In embodiments, the column packing, when present, may also be selected to reduce liquid holdup, as is generally understood by one having reasonable skill in the art, and the like.

Experiments were conducted by simulation to determine the average residence time of the aqueous phase of a second distillation column operated using a top flush stream and partial column reflux in an aldehyde removal system of a commercial acetic acid production process, which produced a residuum stream having an HI concentration which was difficult to control. In comparative examples, an average residence time of the aqueous phase in the distillation zone of the second distillation column which only included bottom drains in the liquid redistributors was determined by simulation to be about 6 hours, which was not reflected in the total residence time of the feed stream in the distillation column. Accordingly, the aqueous phase was being trapped in portions of the column. The column was then simulated to be equipped with drip tubes configured with a first and a second plurality of fluid passages as shown in FIGS. 4, 5, and 6 in separate modeling experiments. Under the same conditions as the comparative example simulation, the average residence time of the aqueous phase in the distillation zone of the inventive distillation columns was reduced from about 6 hours to about 11 minutes on average.

Employment of a second distillation column according to embodiments disclosed herein having an average liquid phase residence time within the distillation zone of about 1 minute to about 60 minutes, wherein the distillation zone comprised a plurality of internal components, each having a component liquid retention volume, wherein each of the internal components was dimensioned and arranged such that an average residence time of the first liquid phase and an average residence time of the second liquid phase in each of the component liquid retention volumes was less than about 30 minutes, resulted in a second column residuum stream having a concentration of HI between 0.11 weight percent and 0.9 weight percent.

In embodiments, the average residence time of the feed stream within the distillation zone of the second distillation column is about 1 minute to about 60 minutes or about 1 minute to about 30 minutes, or about 1 minute to about 15 minutes.

In embodiments the distillation zone comprises a plurality of internal components, each having a component liquid retention volume. Each of the internal components is dimensioned and arranged such that an average residence time of the first liquid phase within the liquid retention volume of each component is less than about 30 minutes, or about 20 minutes, or about 10 minutes, or about 5 minutes. In embodiments, each of the internal components is dimensioned and arranged such that an average residence time of the second liquid phase within the liquid retention volume of each component is less than about 30 minutes, or about 20 minutes, or about 10 minutes, or about 5 minutes, when determined via modeling or direct measurement.

In embodiments, at least one internal component, or all internal components present in the distillation zone is (are) dimensioned and arranged such that the average residence time of the first liquid phase is greater than or equal to the average residence time of the second liquid phase in the corresponding component liquid retention volume when determined via modeling or direct measurement.

In embodiments, at least one internal component e.g., a distillation tray, liquid collector, distributor, or redistributor, comprises a first plurality of flow paths (e.g., 324, 322, and/or 334) dimensioned and arranged such that the average residence time of the first liquid phase is from about 0.1 minutes to about 20 minutes, or to about 10 minutes, or to about 5 minutes in the corresponding component liquid retention volume when determined via modeling or direct measurement.

In embodiments, the at least one internal component further comprises a second plurality of flow paths (e.g., 330 322, 336 and/or 340) dimensioned and arranged such that the average residence time of the second liquid phase is from about 0.1 minutes to about 20 minutes, or to about 10 minutes, or to about 5 minutes in the corresponding component liquid retention volume when determined via modeling or direct measurement.

In embodiments, the concentration of HI in the second column residuum may be controlled by selecting various conditions associated with the second distillation column. In embodiments, the concentration of HI in the second column residuum may be controlled between 0.1 wt % and 0.9 wt % by selecting the temperature and pressures of the distillation, i.e., the bottom temperature of the second distillation column and the pressure of the second distillation column.

In embodiments, the concentration of HI in the second column residuum may be controlled by selecting the composition of the top flush stream, the mass flow rate of the top flush stream, the composition of the bottom flush stream, and/or the mass flow rate of the bottom flush stream. For example, to decrease the concentration of HI in the second column residuum, the amount of bottom flush stream relative to the column feed rate may be increased to dilute and wash out the HI present in the column sump.

In embodiments, the concentration of HI in the second column residuum may be controlled by selecting an average liquid phase residence time in the distillation zone, and/or by controlling the average residence time of one or more liquid phases within the retention volumes of one or more internal components, as discussed herein. In addition, any combination of the above control schemes may be selected to produce the residuum stream comprising about 0.11 weight percent HI to less than or equal to 0.9 weight percent HI.

In embodiments, the process for producing acetic acid may further include introducing a lithium compound into the reactor to maintain the concentration of lithium acetate in an amount from 0.3 to 0.7 wt % in the reaction medium. In embodiments, an amount of the lithium compound is introduced into the reactor to maintain the concentration of hydrogen iodide in an amount from 0.1 to 1.3 wt % in the reaction medium. In embodiments, the concentration of the rhodium catalyst is maintained in an amount from 300 to 3000 wppm in the reaction medium, the concentration of water is maintained in amount from 0.1 to 4.1 wt % in the reaction medium, and the concentration of methyl acetate is maintained from 0.6 to 4.1 wt % in the reaction medium, based on the total weight of the reaction medium present within the carbonylation reactor.

In embodiments, the lithium compound introduced into the reactor is selected from the group consisting of lithium acetate, lithium carboxylates, lithium carbonates, lithium hydroxide, other organic lithium salts, and mixtures thereof. In embodiments, the lithium compound is soluble in the reaction medium. In an embodiment, lithium acetate dihydrate may be used as the source of the lithium compound.

Lithium acetate reacts with hydrogen iodide according to the following equilibrium reaction (I) to form lithium iodide and acetic acid:

LiOAc+HI⇄LiI+HOAc  (I)

Lithium acetate is thought to provide improved control of hydrogen iodide concentration relative to other acetates, such as methyl acetate, present in the reaction medium. Without being bound by theory, lithium acetate is a conjugate base of acetic acid and thus reactive toward hydrogen iodide via an acid—base reaction. This property is thought to result in an equilibrium of the reaction (I) which favors reaction products over and above that produced by the corresponding equilibrium of methyl acetate and hydrogen iodide. This improved equilibrium is favored by water concentrations of less than 4.1 wt % in the reaction medium. In addition, the relatively low volatility of lithium acetate compared to methyl acetate allows the lithium acetate to remain in the reaction medium except for volatility losses and small amounts of entrainment into the vapor crude product. In contrast, the relatively high volatility of methyl acetate allows the material to distill into the purification train, rendering methyl acetate more difficult to control. Lithium acetate is much easier to maintain and control in the process at consistent low concentrations of hydrogen iodide. Accordingly, a relatively small amount of lithium acetate may be employed relative to the amount of methyl acetate needed to control hydrogen iodide concentrations in the reaction medium. It has further been discovered that lithium acetate is at least three times more effective than methyl acetate in promoting methyl iodide oxidative addition to the rhodium [I] complex.

In embodiments, the concentration of lithium acetate in the reaction medium is maintained at greater than or equal to 0.3 wt. %, or greater than or equal to 0.35 wt. %, or greater than or equal to 0.4 wt. %, or greater than or equal to 0.45 wt. %, or greater than or equal to 0.5 wt. %, and/or in embodiments, the concentration of lithium acetate in the reaction medium is maintained at less than or equal to 0.7 wt. %, or less than or equal to 0.65 wt. %, or less than or equal to 0.6 wt. %, or less than or equal to 0.55 wt. %, when determined according to perchloric acid titration to a potentiometric endpoint.

It has been discovered that an excess of lithium acetate in the reaction medium can adversely affect the other compounds in the reaction medium, leading to decrease productivity. Conversely, it has been discovered that a lithium acetate concentration in the reaction medium below about 0.3 wt. % results in a lack of control over hydrogen iodide concentrations within the reaction medium.

In embodiments, the lithium compound may be introduced continuously or intermittently into the reaction medium. In embodiments, the lithium compound is introduced during reactor start up. In embodiments, the lithium compound is introduced intermittently to replace entrainment losses.

A series of experiments conducted to demonstrate the promotional effect of lithium acetate in the carbonylation reactor and to determine the effect of lithium acetate on the methyl iodide oxidative addition to the rhodium complex, Li[RhI₂(CO)₂] confirmed the promotional effect of lithium acetate on reaction rates. A linear increase of reaction rates correlated to increasing lithium acetate concentrations was observed. This correlation was indicative of first order promotional effects of reaction between methyl iodide and Li[RhI₂(CO)₂]. These experiments further showed a non-zero intercept, confirming that lithium acetate is not required for the MeI—Rh(I) reaction to occur, but the lithium acetate does give considerable promotional effect even at low concentrations.

In embodiments, the process may further comprise maintaining a butyl acetate concentration in the acetic acid product at 10 wppm or less without directly removing butyl acetate from the product acetic acid. In embodiments, the butyl acetate concentration in the final acetic acid product may be maintained below 10 ppm by removing acetaldehyde from the reaction medium, e.g., removing acetaldehyde from a stream derived from the reaction medium, and/or by controlling the reaction temperature, and/or the hydrogen partial pressure, and/or the metal catalyst concentration in the reaction medium. In embodiments, the butyl acetate concentration in the final acetic acid product is maintained by controlling one or more of the carbonylation reaction temperature from 150° C. to 250° C., the hydrogen partial pressure in the carbonylation reactor at from 0.3 to 2 atm, the rhodium metal catalyst concentration in the reaction medium at from 100 to 3000 wppm, based on the total weight of the reaction medium, and/or the acetaldehyde concentration in the reaction medium at 1500 ppm or less.

In embodiments, the acetic acid product formed according to embodiments of the process disclosed herein has a butyl acetate concentration of less than or equal to 10 wppm, or less than or equal to 9 wppm, or less than or equal to 8 wppm, or less than or equal to 6 wppm, or less than or equal to 2 wppm, based on the total weight of the acetic acid product. In embodiments, the acetic acid product is substantially free of butyl acetate, i.e., a butyl acetate concentration of less than 0.05 wppm or is non-detectable by detection means known in the art. In embodiments, the acetic acid product may also have a propionic acid concentration of less than 250 wppm, or less than 225 ppm, or less than 200 wppm.

In embodiments, the butyl acetate concentration in the acetic acid product may be controlled by controlling the concentration of acetaldehyde in the reaction medium. While not wishing to be bound by theory, butyl acetate is thought to be a by-product caused by aldol condensation of acetaldehyde. Applicant has discovered that by maintaining the acetaldehyde concentration in the reaction medium at less than 1500 wppm, the concentration of butyl acetate in the final acetic acid product may be controlled below 10 wppm. In embodiments, the acetaldehyde concentration in the reaction medium is maintained at less than or equal to 1500 wppm, or less than or equal to 900 wppm, or less than or equal to 500 wppm, or less than or equal to 400 wppm, based on the total weight of the reaction medium.

In embodiments, the butyl acetate concentration in the acetic acid product may be controlled by controlling the reaction temperature of the carbonylation reactor at a temperature greater than or equal to 150° C., or 180° C., and less than or equal to 250° C., or 225° C.; and/or the hydrogen partial pressure in the carbonylation reactor may be controlled at greater than or equal to 0.3 atm, or 0.35 atm, or 0.4 atm, or 0.5 atm, and less than or equal to 2 atm, or 1.5 atm, or 1 atm.

While relatively high hydrogen partial pressure results in improved reaction rates, selectivity, improved catalyst activity, and reduced temperatures, applicant has discovered that as hydrogen partial pressure is increased, impurity production is also increased, including butyl acetate.

In embodiments, the hydrogen partial pressure may be controlled by modifying the amount of hydrogen present in the carbon monoxide source and/or by increasing or decreasing the reactor vent flows to obtain the desired hydrogen partial pressure within the carbonylation reactor.

A series of experiments were conducted to demonstrate the effect of hydrogen partial pressure and acetaldehyde concentration in the reaction medium on the concentration of butyl acetate in the final acetic acid product. These experiments confirmed a correlation between reduced butyl acetated concentrations in the final acetic acid product, and relatively low acetaldehyde concentrations in the reaction medium and/or relatively low hydrogen partial pressures in the carbonylation reactor. Experiments in which the acetaldehyde concentration in the reactor was maintained below 1500 ppm and the reactor hydrogen partial pressure maintained below 0.6 atm resulted in butyl acetate levels below 10 wppm in the final acetic acid product. Other experiments showed an acetaldehyde concentration in the reactor below 1500 wppm and a reactor hydrogen partial pressure of 0.46 atm resulted in a butyl acetate concentration of less than 8 wppm in the final acetic acid product. Similar conditions in which the hydrogen partial pressure was 0.30 atm resulted in butyl acetate levels below 6 wppm, and hydrogen partial pressures of 0.60 atm resulted in butyl acetate concentrations below 0.2 wppm in the final acetic acid product. However, comparative experiments in which the hydrogen partial pressure was 0.4 and 0.3 respectively, but in the absence of an aldehyde removal system such that the acetaldehyde concentrations in the reactor exceeded 1500 wppm, resulted in a final acetic acid product having butyl acetate levels of 13 wppm and 16 wppm respectively.

Applicant has further discovered that the concentration of propionic acid in the final acetic acid product may be affected by the concentration butyl acetate in the acetic acid product. Accordingly, by controlling the butyl acetate concentration in the final acetic acid product to 10 wppm or less, the concentration of propionic acid in the final acetic acid product may be controlled to less than 250 wppm, or less than 225 ppm, or less than 200 wppm. Likewise, by controlling the ethanol content in the reactor feed, which may be present as an impurity in the methanol source, the propionic acid and butyl acetate concentrations in the final acetic acid product may also be controlled. In embodiments, the concentration of ethanol in the methanol feed to the carbonylation reactor is controlled to less than or equal to 150 wppm. In embodiments, if present, the ethanol concentration in the methanol feed to the reactor is less than or equal to 100 wppm, or 50 wppm, or 25 wppm.

Applicant has further discovered that the formation of ethyl iodide may be affected by numerous variables, including the concentration of acetaldehyde, ethyl acetate, methyl acetate and methyl iodide in the reaction medium. Additionally, ethanol content in the methanol source, hydrogen partial pressure and hydrogen content in the carbon monoxide source have been discovered to affect ethyl iodide concentration in the reaction medium and, consequently, propionic acid concentration in the final acetic acid product.

In embodiments, the concentration of ethyl iodide in the reaction medium is maintained/controlled to be less than or equal to 750 wppm, or less than or equal to 650 wppm, or less than or equal to 550 wppm, or less than or equal to 450 wppm, or less than or equal to 350 wppm. In alternative embodiments, the concentration of ethyl iodide in the reaction medium is maintained/controlled at greater than or equal to 1 wppm, or 5 wppm, or 10 wppm, or 20 wppm, or 25 wppm, and less than or equal to 650 wppm, or 550 wppm, or 450 wppm, or 350 wppm.

In embodiments, the propionic acid concentration in the acetic acid product may further be maintained below 250 wppm by maintaining the ethyl iodide concentration in the reaction medium at less than or equal to 750 wppm without removing propionic acid from the acetic acid product.

In embodiments, the ethyl iodide concentration in the reaction medium and propionic acid in the acetic acid product may be present in a weight ratio from 3:1 to 1:2, or from 5:2 to 1:2, or from 2:1 to 1:2. In embodiments, the acetaldehyde:ethyl iodide concentration in the reaction medium is maintained at a weight ratio from 2:1 to 20:1, or from 15:1 to 2:1, or from 9:1 to 2:1.

In embodiments, the ethyl iodide concentration in the reaction medium may be maintained by controlling at least one of the hydrogen partial pressure, the methyl acetate concentration, the methyl iodide concentration, and/or the acetaldehyde concentration in the reaction medium.

A series of experiments conducted to determine the effect of acetaldehyde and other reaction conditions on the formation of ethyl indicated a relationship between acetaldehyde concentration and ethyl iodide concentration in the reaction medium, as well as relationships between the reactor concentration of ethyl iodide and the concentration of propionic acid in the final acetic acid product. In general, an ethyl iodide concentration of less than 750 wppm and an acetaldehyde concentration of less than 1500 wppm in the reaction medium resulted in propionic acid concentrations of less than 250 wppm in the acetic acid product.

As is evident from the figures and text presented above, a variety of embodiments are contemplated.

-   -   E1. A process comprising:         -   providing a feed stream comprising methyl iodide, water,             acetic acid, methyl acetate, and at least one PRC to a             distillation column comprising a distillation zone and a             bottom sump zone;         -   distilling the feed stream at a pressure and a temperature             sufficient to produce an overhead stream comprising methyl             iodide and at least one PRC, and a residuum stream flowing             from the bottom sump zone comprising water and greater than             or equal to about 0.11 weight percent HI, wherein a total             amount of HI exiting the distillation column in the overhead             stream and the residuum stream is greater than an amount of             HI entering the distillation column, if any, in the feed             stream.     -   E2. The process according to embodiment E1, wherein the residuum         stream comprises about 0.6 weight percent HI to about 1.2 weight         percent HI.     -   E3. The process according to embodiment E1 or E2, wherein an         average liquid phase residence time within the distillation zone         is about 1 minute to about 60 minutes.     -   E4. The process according to any one of embodiments E1 to E3,         wherein the liquid phase comprises a first liquid phase         comprising greater than about 50 weight percent water and a         second liquid phase comprising greater than about 50 weight         percent methyl iodide.     -   E5. The process according to any one of embodiments E1 to E4,         wherein the distillation zone comprises a plurality of internal         components, each having a component liquid retention volume,         wherein each of the internal components is dimensioned and         arranged such that an average residence time of the first liquid         phase and an average residence time of the second liquid phase         in each of the component liquid retention volumes is less than         about 30 minutes.     -   E6. The process according to embodiment E5, wherein at least one         internal component is dimensioned and arranged such that the         average residence time of the first liquid phase is greater than         or equal to the average residence time of the second liquid         phase in the corresponding component liquid retention volume.     -   E7. The process according to embodiment E5 or E6, wherein at         least one internal component comprises a first plurality of flow         paths dimensioned and arranged such that the average residence         time of the first liquid phase is from about 0.1 minutes to         about 20 minutes in the corresponding component liquid retention         volume.     -   E8. The process according to any one of embodiments E5 to E7,         wherein the at least one internal component further comprises a         second plurality of flow paths dimensioned and arranged such         that the average residence time of the second liquid phase is         from about 0.1 minutes to about 20 minutes in the corresponding         component liquid retention volume.     -   E9. The process according to any one of embodiments E1 to E8,         further comprising directing a top flush stream comprising water         into the distillation zone.     -   E10. The process according to embodiment E9, wherein a mass flow         rate of the top flush stream is greater than or equal to about         0.1 percent of the mass flow rate of the feed stream.     -   E11. The process according to embodiment E9 or E10, wherein the         top flush stream comprises greater than or equal to about 20         weight percent water, a portion of the bottom residuum stream,         or a combination thereof.     -   E12. The process according to any one of embodiments E1 to E11,         further comprising directing a bottom flush stream comprising         acetic acid into the distillation zone, the bottom sump zone, or         both.     -   E13. The process according to embodiment E12, wherein the bottom         flush stream comprises greater than or equal to about 20 weight         percent acetic acid.     -   E14. The process according to embodiment E12 or E13, wherein a         mass flow rate of the bottom flush stream is greater than or         equal to about 0.1 percent of the mass flow rate of the feed         stream.     -   E15. The process according to any one of embodiments E1 to E14,         wherein the overhead stream comprises dimethyl ether.     -   E16. A process according to any one of embodiments E1 to E15,         further comprising:         -   a. distilling a portion of a reaction medium of a             carbonylation reactor in a first column to yield an acetic             acid stream which is further purified to produce an acetic             acid product, and a first overhead stream comprising methyl             iodide, water, acetic acid, methyl acetate, and at least one             PRC;         -   b. directing a second column feed stream comprising or             derived from the first overhead stream into a second             distillation column comprising a distillation zone and a             bottom sump zone;         -   c. distilling the second column feed stream at a pressure             and a temperature sufficient to produce a second column             overhead stream comprising methyl iodide and at least one             PRC, and a second column residuum stream flowing from the             bottom sump zone comprising water and greater than or equal             to about 0.11 weight percent HI;         -   d. extracting at least a portion of the second column             overhead stream comprising methyl iodide and at least one             PRC with water to produce an aqueous waste stream comprising             the at least one PRC, and a raffinate stream comprising             methyl iodide; and         -   e. directing at least a first portion of the raffinate             stream back into the second distillation column, wherein a             total amount of HI exiting the distillation column in the             overhead stream and the residuum stream is greater than an             amount of HI entering the distillation column, if any, in             the feed stream.     -   E17. A process comprising:         -   a. distilling a portion of a reaction medium of a             carbonylation reactor in a first column to yield an acetic             acid stream, which is further purified to produce an acetic             acid product, and a first overhead stream comprising methyl             iodide, water, acetic acid, methyl acetate, and at least one             PRC;         -   b. directing a second column feed stream comprising or             derived from the first overhead stream into a second             distillation column comprising a distillation zone and a             bottom sump zone;         -   c. distilling the second column feed stream at a pressure             and a temperature sufficient to produce a second column             overhead stream comprising methyl iodide and at least one             PRC, and a second column residuum stream flowing from the             bottom sump zone comprising water and greater than or equal             to about 0.11 weight percent HI;         -   d. extracting at least a portion of the second column             overhead stream comprising methyl iodide and at least one             PRC with water to produce an aqueous waste stream comprising             the at least one PRC, and a raffinate stream comprising             methyl iodide; and         -   e. directing at least a first portion of the raffinate             stream back into the second distillation column.     -   E18. The process according to embodiment E16 or E17, wherein the         second column residuum stream comprises about 0.6 weight percent         HI to about 1.2 weight percent HI.     -   E19. The process according to any one of embodiments E16 to E18,         wherein the second column overhead stream comprises dimethyl         ether.     -   E20. The process according to any one of embodiments E16 to E19,         wherein an average liquid phase residence time within the         distillation zone of the second distillation column is about 1         minute to about 60 minutes.     -   E21. The process according to any one of embodiments E16 to E20,         further comprising directing a top flush stream comprising water         into the distillation zone of the second distillation column.     -   E22. The process according to any one of embodiments E16 to E21,         wherein a mass flow rate of the top flush stream is greater than         or equal to about 0.1 percent of the mass flow rate of the         second column feed stream.     -   E23. The process according to embodiment E22, wherein the top         flush stream comprises greater than or equal to about 20 weight         percent water, a portion of the bottom residuum stream, or a         combination thereof.     -   E24. The process according to any one of embodiments E16 to E23,         further comprising directing a bottom flush stream comprising         acetic acid into the distillation zone and/or the bottom sump         zone of the second distillation column.     -   E25. The process according to embodiment E24, wherein the bottom         flush stream comprises greater than or equal to about 20 weight         percent acetic acid.     -   E26. The process according to any one of embodiments E16 to E25,         further comprising:         -   f. directing a second portion of the raffinate stream             comprising methyl iodide and dimethyl ether back into the             reaction medium.     -   E27. The process according to embodiment E26, wherein a mass         flow rate of the first portion of the raffinate stream is         greater than or equal to a mass flow rate of the second portion         of the raffinate stream.     -   E28. The process according to any one of embodiments E1 to E27,         wherein a bottom temperature of the second distillation column         is about 90° C. to about 130° C., a pressure of the second         distillation column is from atmospheric pressure to about 700         kPa above atmospheric pressure, or a combination thereof.     -   E29. A process comprising:         -   a. distilling a portion of a reaction medium of a             carbonylation reactor in a first distillation column to             yield an acetic acid stream, which is further purified to             produce an acetic acid product, and a first overhead stream             comprising methyl iodide, water, acetic acid, methyl             acetate, and at least one PRC;         -   b. directing a second column feed stream comprising or             derived from the first overhead stream into a second             distillation column comprising a distillation zone and a             bottom sump zone;         -   c. distilling the second column feed stream at a pressure             and a temperature sufficient to produce a second column             overhead stream comprising methyl iodide, dimethyl ether,             and at least one PRC, and a second column residuum stream             flowing from the bottom sump zone comprising water and from             about 0.11 weight percent to about 0.9 weight percent HI;         -   d. directing a top flush stream comprising water into the             distillation zone at a mass flow rate greater than or equal             to 0.1% of the mass flow rate of the second column feed             stream; and         -   e. directing a bottom flush stream comprising acetic acid             into the distillation zone and/or the bottom sump zone at a             mass flow rate greater than or equal to 0.1% of the mass             flow rate of the second column feed stream.         -   E30. The process according to any one of embodiments E1 to             E29, wherein a bottom temperature of the second distillation             column, a pressure of the second distillation column, a             composition of the top flush stream, the mass flow rate of             the top flush stream, a composition of the bottom flush             stream, the mass flow rate of the bottom flush stream, an             average liquid phase residence time in the distillation             zone, or a combination thereof, are selected to produce the             residuum stream comprising about 0.6 weight percent HI to             less than or equal to 1.2 weight percent HI.     -   E31. The process according to any one of embodiments E1 to E30,         further comprising introducing a lithium compound selected from         the group consisting of lithium acetate, lithium carboxylates,         lithium carbonates, lithium hydroxide, and mixtures thereof into         the reaction medium to maintain the concentration of lithium         acetate between 0.3 and 0.7 wt % in the reaction medium.     -   E32. The process according to embodiment E31, further         comprising:         -   a. maintaining the concentration of hydrogen iodide is             maintained between 0.1 and 1.3 wt % in the reaction medium;         -   b. maintaining the concentration of the rhodium catalyst at             between 300 and 3000 wppm in the reaction medium, determined             as rhodium metal;         -   c. maintaining wherein the concentration of water is             maintained between 0.1 and 4.1 wt % in the reaction medium;         -   d. maintaining the concentration of methyl acetate between             0.6 and 4.1 wt % in the reaction medium;         -   e. or a combination thereof.     -   E33. The process according to any one of embodiments E1 to E32,         further comprising controlling a butyl acetate concentration in         the acetic acid product at 10 wppm or less without directly         removing butyl acetate from the acetic acid product.     -   E34. The process according to embodiment E33, wherein the butyl         acetate concentration is controlled by maintaining an         acetaldehyde concentration in the reaction medium at 1500 ppm or         less, controlling a temperature in the carbonylation reactor         from 150 to 250° C., controlling a hydrogen partial pressure in         the carbonylation reactor from 0.3 to 2 atm, controlling a         rhodium metal catalyst concentration in the reaction medium from         100 to 3000 wppm, based on the total weight of the reaction         medium, or a combination thereof.     -   E35. The process according to any one of embodiments E1 to E34,         further comprising controlling an ethyl iodide concentration in         the reaction medium at less than or equal to 750 wppm, and         wherein the acetic acid product comprises less than 250 wppm         propionic acid without directly removing propionic acid from the         acetic acid product. E36. The process according to embodiment         E35, wherein ethyl iodide in the reaction medium and propionic         acid in the acetic acid product are present in a weight ratio         from 3:1 to 1:2.     -   E37. The process according to embodiment E35 or E36, wherein         acetaldehyde and ethyl iodide are present in the reaction medium         in a weight ratio from 2:1 to 20:1.     -   E38. The process according to any one of embodiments E35 to E37,         wherein the methanol is introduced into the reactor in a         methanol source comprising from 1 to 150 wppm ethanol.     -   E39. The process according to any one of embodiments E35 to E38,         wherein the ethyl iodide concentration in the reaction medium is         controlled by adjusting at least one of a hydrogen partial         pressure in the carbonylation reactor, a methyl acetate         concentration in the reaction medium, and a methyl iodide         concentration in the reaction medium.     -   E40. The process according to any one of embodiments E1 to E39,         comprising:         -   a. carbonylating a reactant feed stream comprising methanol,             methyl acetate, dimethyl ether, or mixtures thereof in a             reactor in the presence of a water, rhodium catalyst, iodide             salt and methyl iodide to form a reaction medium;         -   b. distilling a stream derived from the reaction medium in a             first column to yield an acetic acid stream which is further             purified to produce a product acetic acid stream, and a             first overhead stream comprising methyl iodide, water,             acetic acid, methyl acetate, and at least one PRC;         -   c. biphasically separating the first overhead stream into a             light phase comprising greater than about 30 wt % water,             acetic acid, methyl acetate, at least one PRC, and a heavy             phase comprising water, acetic acid, methyl acetate, at             least one PRC, and greater than about 30 wt % methyl iodide;         -   d. directing a second column feed stream comprising or             derived from the light phase, the heavy phase, or a             combination thereof into a second distillation column             comprising a distillation zone and a bottom sump zone,             wherein a total amount of HI exiting the distillation column             in the overhead stream and the residuum stream is greater             than an amount of HI entering the distillation column, if             any, in the feed stream.     -   E41. The process according to embodiment E40, wherein the second         column feed stream comprises from 10 wt % to 90 wt % of the         light phase, and from 10 wt % to 90 wt % of the heavy phase,         based on the total amount of the first column overhead present         in the second column feed stream.     -   E42. The process according to any one of embodiments E1 to E41,         wherein the acetic acid stream is further purified by         distillation in a drying column to remove water, in a heavy ends         column, and/or contacted with one or more absorbents,         adsorbents, or purification resins in guard column to produce         the product acetic acid stream.     -   E43. A process comprising:         -   a. providing a second column feed stream comprising methyl             iodide, water, acetic acid, methyl acetate, and at least one             PRC to a second distillation column comprising a             distillation zone and a bottom sump zone;         -   b. distilling the second column feed stream at a pressure             and a temperature sufficient to produce a second column             overhead stream comprising methyl iodide and at least one             PRC, and a residuum stream flowing from the bottom sump zone             comprising water and greater than or equal to about 0.11             weight percent HI, wherein a total amount of HI exiting the             distillation column in the overhead stream and the residuum             stream is greater than an amount of HI entering the             distillation column, if any, in the feed stream.     -   E44. The process according to embodiment E43, wherein the         residuum stream comprises about 0.6 weight percent HI to about         1.2 weight percent HI.     -   E45. The process according to embodiment E43 or E44, wherein an         average liquid phase residence time within the distillation zone         is about 1 minute to about 60 minutes;         -   wherein the liquid phase within the distillation zone             comprises a first liquid phase comprising greater than about             50 weight percent water and a second liquid phase comprising             greater than about 50 weight percent methyl iodide;         -   wherein the distillation zone comprises a plurality of             internal components, each having a component liquid             retention volume and each of the internal components is             dimensioned and arranged such that an average residence time             of the first liquid phase and an average residence time of             the second liquid phase in each of the component liquid             retention volumes is less than about 30 minutes; or a             combination thereof.     -   E46. The process according to embodiment E45, wherein at least         one internal component is dimensioned and arranged such that the         average residence time of the first liquid phase is greater than         or equal to the average residence time of the second liquid         phase in the corresponding component liquid retention volume;         -   wherein at least one internal component comprises a first             plurality of flow paths dimensioned and arranged such that             the average residence time of the first liquid phase is from             about 0.1 minutes to about 20 minutes in the corresponding             component liquid retention volume;         -   wherein, at least one internal component further comprises a             second plurality of flow paths dimensioned and arranged such             that the average residence time of the second liquid phase             is from about 0.1 minutes to about 20 minutes in the             corresponding component liquid retention volume; or a             combination thereof.     -   E47. The process according to any one of embodiments E43 to E46,         further comprising directing a top flush stream comprising water         into the distillation zone at a mass flow rate greater than or         equal to about 0.1 percent of the mass flow rate of the feed         stream;         -   further comprising directing a bottom flush stream             comprising acetic acid into the distillation zone, the             bottom sump zone, or both at a mass flow rate greater than             or equal to about 0.1 percent of the mass flow rate of the             feed stream, or a combination thereof.     -   E48. The process according to any one of embodiments E43 to E47,         wherein the second column overhead stream comprises dimethyl         ether.     -   E49. The process according to any one of embodiments E43 to E48,         wherein the second column feed stream is produced by distilling         a stream derived from a reaction medium of a carbonylation         reactor in a first column to yield an acetic acid stream which         is then purified to produce a product acetic acid stream, and a         first overhead stream comprising methyl iodide, water, acetic         acid, methyl acetate, and at least one PRC, and biphasically         separating the first column overhead to produce a light phase         comprising methyl iodide, acetic acid, methyl acetate, at least         one PRC, and greater than about 30 wt % water, and a heavy phase         comprising water, acetic acid, methyl acetate, at least one PRC,         and greater than about 30 wt % methyl iodide; and wherein said         second column feed stream comprises at least a portion of the         light phase, the heavy phase, or a combination thereof.     -   E50. The process according to embodiment E49, wherein the second         column feed stream comprises from 10 wt % to 90 wt % of the         light phase and from 90 wt % to 10 wt % of the heavy phase,         based on the total amount of the first column overhead present         in the feed stream.     -   E51. The process according to embodiment E49 or E50, further         comprising extracting at least a portion of the second column         overhead stream with water to produce an aqueous waste stream         comprising the at least one PRC, and a raffinate stream         comprising methyl iodide; and directing at least a first portion         of the raffinate stream back into the second distillation         column.     -   E52. The process according to embodiment E51, wherein the second         column overhead stream comprises dimethyl ether and further         comprising directing a second portion of the raffinate stream         comprising methyl iodide and dimethyl ether back into the         reaction medium.     -   E53. The process according to embodiment E52, wherein a mass         flow rate of the first portion of the raffinate stream is         greater than or equal to a mass flow rate of the second portion         of the raffinate stream;         -   wherein a bottom temperature of the second distillation             column is about 90° C. to about 130° C.,         -   wherein a pressure of the second distillation column is from             atmospheric pressure to about 700 kPa above atmospheric             pressure, or a combination thereof.

While the embodiments have been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only some embodiments have been shown and described and that all changes and modifications that come within the spirit of the embodiments are desired to be protected. It should be understood that while the use of words such as ideally, desirably, preferable, preferably, preferred, more preferred or exemplary utilized in the description above indicate that the feature so described may be more desirable or characteristic, nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. 

1-19. (canceled)
 20. A process to separate a mixture comprising methyl iodide, water, acetic acid, methyl acetate, and at least one permanganate reducing compound (PRC) derived from a condensed, biphasically separated first overhead stream produced by distilling a portion of a reaction medium of a carbonylation reactor in a first distillation column to yield an acetic acid product side stream and the first overhead stream, the process comprising: providing a second distillation column feed stream comprising the mixture to a second distillation column comprising a distillation zone and a bottom sump zone; directing a top flush stream comprising water into the distillation zone; distilling the second distillation column feed stream to produce a second column overhead stream comprising methyl iodide and at least one PRC, a second column residuum stream flowing from the bottom sump zone comprising HI; and a second column sidestream of the second distillation column comprising methyl acetate, wherein the total amount of HI exiting the second distillation column in the second column overhead stream, the second column residuum stream, and the second column sidestream is greater than a total amount of HI entering the second distillation column, if any, in the second distillation column feed stream.
 21. The process of claim 20, wherein the second column residuum stream comprises greater than or equal to about 0.11 weight percent HI, based on the total amount of the second column residuum stream.
 22. The process of claim 20, wherein a portion of the second column overhead stream is condensed, separated, and directed back into the second distillation column.
 23. The process of claim 20, wherein the second column sidestream is recycled back into the process.
 24. The process of claim 20, wherein a mass flow rate of the top flush stream into the second distillation column is greater than or equal to about 0.1 percent of a mass flow rate of the second column feed stream.
 25. The process of claim 20, further comprising directing a bottom flush stream comprising water, acetic acid, or both into the distillation zone of the second distillation column, the bottom sump zone of the second distillation column, or both, at a mass flow rate of greater than or equal to about 0.1 percent of a mass flow rate of the second column feed stream.
 26. The process of claim 25, wherein the bottom flush stream is directed into the second distillation column between an exit of the second column sidestream and the bottom of the second distillation column.
 27. The process of claim 20, wherein the second column sidestream exits the second distillation column from the distillation zone of the second distillation column.
 28. The process of claim 20, wherein the second column overhead comprises dimethyl ether.
 29. The process of claim 20, wherein the biphasically separated first overhead stream comprises a light aqueous phase comprising greater than about 30 wt % water, and a heavy phase comprising greater than about 30 wt % methyl iodide, and wherein the second column feed stream is derived from, or comprises a portion of the light aqueous phase.
 30. The process of claim 20, wherein: i. the reaction medium of a carbonylation reactor comprises a lithium acetate concentration between 0.3 and 0.7 wt % in the reaction medium; ii. the concentration of hydrogen iodide is from 0.1 to 1.3 wt % in the reaction medium, based on the total weight of the reaction medium; iii. the concentration of a rhodium catalyst is from 100 to 3000 wppm in the reaction medium, based on the total weight of the reaction medium; iv. the concentration of water is from 0.1 to 4.1 wt % in the reaction medium, based on the total weight of the reaction medium; v. the concentration of methyl acetate is from 0.6 to 4.1 wt % in the reaction medium, based on the total weight of the reaction medium; or a combination thereof.
 31. The process of claim 20, wherein a butyl acetate concentration in the acetic acid product side stream is 10 wppm or less without directly removing butyl acetate from the acetic acid product side steam, wherein the butyl acetate concentration in the acetic acid product side stream is controlled by: i. maintaining an acetaldehyde concentration in the reaction medium at 1500 ppm or less, based on the total weight of the reaction medium; ii. controlling a temperature in the carbonylation reactor from 150° C. to 250° C.; iii. controlling a hydrogen partial pressure in the carbonylation reactor from 0.3 to 2 atm; iv. controlling a rhodium metal catalyst concentration in the reaction medium from 100 to 3000 wppm, based on the total weight of the reaction medium; or a combination thereof.
 32. The process of claim 20, wherein an ethyl iodide concentration in the reaction medium is less than or equal to 750 wppm, wherein the acetic acid product side stream comprises less than 250 wppm propionic acid without directly removing propionic acid from the acetic acid product stream, or a combination thereof, wherein: i. ethyl iodide in the reaction medium and propionic acid in the acetic acid product side stream are present in a weight ratio from 3:1 to 1:2; ii. acetaldehyde and ethyl iodide are present in the reaction medium in a weight ratio from 2:1 to 20:1; iii. methanol introduced into the carbonylation reactor comprises less than 150 wppm ethanol; iv. an ethyl iodide concentration in the reaction medium is controlled by adjusting a hydrogen partial pressure in the carbonylation reactor, a methyl acetate concentration in the reaction medium, a methyl iodide concentration in the reaction medium; or a combination thereof.
 33. A process to produce acetic acid, comprising: a. carbonylating a reaction medium comprising a reactant feed stream comprising methanol, methyl acetate, dimethyl ether, or mixtures thereof, water, a rhodium catalyst, an iodide salt and methyl iodide in a reactor to form acetic acid and directing a portion of the reaction medium into a flasher to produce a vapor product stream comprising acetic acid, water, methyl iodide, methyl acetate and at least one permanganate reducing compound (PRC), and a non-volatile stream and directing the non-volatile stream back into the reaction medium; b. directing the vapor product stream from the flasher into a first distillation column to produce an acetic acid side stream, and a first column overhead stream comprising methyl iodide, water, acetic acid, methyl acetate, and at least one PRC; c. biphasically separating the first column overhead stream into a light phase comprising methyl iodide, acetic acid, methyl acetate, at least one PRC, and greater than about 30 wt % water, and a heavy phase comprising water, acetic acid, methyl acetate, at least one PRC, and greater than about 30 wt % methyl iodide; d. directing a second distillation column feed stream comprising or derived from a portion of the light phase, the heavy phase, or a combination thereof, into a second distillation column comprising a distillation zone and a bottom sump zone; e. directing a top flush stream comprising water into the distillation zone at a mass flow rate greater than or equal to 0.1% of the mass flow rate of the second distillation column feed stream; f. distilling the second distillation column feed stream at a pressure and a temperature sufficient to produce a second distillation column overhead stream comprising methyl iodide, and at least one PRC, a second column residuum stream comprising HI flowing out of the second column from the bottom sump zone, and a second column sidestream comprising methyl acetate flowing out of the second distillation column at a point between an inlet of the top flush stream and the outlet of the second column residuum stream, wherein the total amount of HI exiting the second distillation column in the second column overhead stream, the second column sidestream, and the second column residuum stream is greater than a total amount of HI entering the second distillation column, if any, in the second distillation column feed stream.
 34. The process of claim 33, wherein the second column residuum stream comprises less than or equal to about 10 weight percent HI, based on the total amount of the second column residuum stream.
 35. The process of claim 33, wherein a portion of the second column overhead stream is condensed, separated, and directed back into the second distillation column.
 36. The process of claim 33, wherein the second column sidestream of the second distillation column is recycled back into the process.
 37. The process of claim 33, wherein the second distillation column overhead comprises dimethyl ether. 